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SICK GM35, Cross-duct version Operating instructions

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MMMOPERATING INSTRUCTIONS
OPERATING INSTRUCTIONS
GM35
Gas Analyzer for CO, N
2
O, CO
2
and H
2
O
Cross-Duct Version
Installation, Operation, Maintenance
Title Page
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Described Product
Product name: GM35
Variants: Cross Duct
Manufacturer
SICK AG
Erwin-Sick-Str. 1 · 79183 Waldkirch · Germany
Phone: +49 7641 469-0
Fax: +49 7641 469-1149
E-Mail: [email protected]
Place of Manufacture
SICK AG
Nimburger Str. 11 · D-79276 Reute · Germany
Legal Information
This work is protected by copyright. All rights derived from the copyright shall
be reserved for SICK AG. Reproduction of this document or parts of this document is
only permissible within the limits of the legal determination of Copyright Law.
Any modification, shortening or translation of this document is prohibited without the
written permission of SICK AG.
The trademarks stated in this document are the property of their respective owner.
© SICK AG. All rights reserved.
Original document
This document is an original document of SICK AG.
CONTENTS
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1 Safety Information..................................................................................... 7
1.1 Permissible users............................................................................................ 7
1.2 Correct handling.............................................................................................. 7
1.3 Safety............................................................................................................... 7
1.4 Behavior during purge air failure.................................................................... 8
2 Product Overview ....................................................................................... 9
2.1 Use and proper application ............................................................................ 9
2.1.1 Conformities and certifications ...................................................... 9
2.1.2 Overview of standard components ..............................................10
2.2 Device components ......................................................................................12
2.2.1 GM35 options and accessories ...................................................13
2.3 Functional principle ......................................................................................14
2.3.1 Opto-electronic in-situ measuring principle.................................14
2.3.2 Signal evaluation ..........................................................................15
2.3.3 Automatic check cycles ................................................................15
3 Project Planning Information.................................................................17
3.1 Work steps from system selection to start-up .............................................17
3.2 Project Planning Checklist ............................................................................18
3.3 Initial onsite installation ...............................................................................20
3.3.1 Assembly preparation at the measuring point ............................20
3.3.2 Uncovering the duct......................................................................20
3.3.3 Installing the flanges with tube ....................................................21
3.3.4 Installation preparation for the purge air unit .............................24
3.3.5 Duct insulation..............................................................................24
3.3.6 Installation preparation for the evaluation unit ..........................25
3.4 Preparations for electrical installation .........................................................25
3.4.1 Electrical installation safety information .....................................26
3.5 Electrical protection ......................................................................................27
3.6 Specifications on electric isolation of the EvU.............................................27
3.7 Laying connection lines ................................................................................28
3.7.1 CAN bus wiring ..............................................................................29
4 Installation ................................................................................................30
4.1 Preparations ..................................................................................................30
4.1.1 Checking the scope of delivery ....................................................30
4.1.2 Installation prerequisites..............................................................30
4.2 Fitting system components...........................................................................31
4.2.1 Information on installing the SR-unit and reflector.....................31
4.2.2 Installing the purge air unit ..........................................................31
4.2.3 Terminal box (option)....................................................................32
4.3 Installing the evaluation unit ........................................................................33
4.3.1 Installing the evaluation unit – sheet metal enclosure version .33
4.3.2 Installing the evaluation unit – cast enclosure version ..............34
CONTENTS
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4.4 Electrical connection of system components.............................................. 35
4.4.1 Electrical connection for the purge air unit................................. 35
4.4.2 CAN bus wiring options ................................................................ 36
4.4.3 Electrical connection in the evaluation unit EvU ........................ 38
5 Handling the Evaluation Unit ................................................................. 41
5.1 User qualifications........................................................................................ 41
5.2 Operating elements ...................................................................................... 41
5.2.1 Function buttons and menu overview ......................................... 42
5.2.2 Display contents ........................................................................... 43
5.2.3 Menu structure ............................................................................. 43
5.2.3.1 Menu structure Measuring Mode ............................ 43
5.2.3.2 Menu structure Diagnosis ........................................ 44
5.2.3.3 Menu structure Calibration ...................................... 44
5.2.3.4 Menu structure Configuration .................................. 45
5.2.3.5 Menu structure Maintenance Mode (Maint) ........... 46
6 Connecting the System Control Unit - SCU........................................... 47
6.1 SCU connection to the GM35....................................................................... 47
6.1.1 Electrical connection of the SCU to the GM35 ........................... 47
6.1.2 Configuring and operating using SOPAS ..................................... 47
6.1.3 Connecting the GM35 evaluation unit via the SCU operating
unit ................................................................................................ 49
6.1.4 Direct serial connection to the GM35 evaluation unit .............. 51
6.1.5 Changing the user level ............................................................... 53
6.1.6 Menu overview (menu tree) ........................................................ 54
6.1.7 Measured values .......................................................................... 54
6.1.8 Menu Parameter .......................................................................... 55
6.1.9 Menu Adjustment ......................................................................... 60
6.1.10 Menu Diagnosis............................................................................ 64
6.1.11 Menu Maintenance ...................................................................... 66
7 Start-up...................................................................................................... 69
7.1 Preparations ................................................................................................. 69
7.1.1 Required qualifications and further prerequisites...................... 69
7.1.2 Start-up procedure overview........................................................ 69
7.2 Start-up steps overview ................................................................................ 69
7.3 Mechanical preparations for the SR-unit and reflector .............................. 71
7.3.1 Checking the scope of delivery .................................................... 71
7.3.2 Transport safety devices .............................................................. 71
7.3.3 Cleaning optical interfaces .......................................................... 72
7.3.4 Information on fitting the SR-unit and reflector.......................... 72
7.4 Measuring path free from sample gas - zero path ...................................... 72
7.4.1 Preparing a zero path................................................................... 72
7.4.2 Installing the GM35 system components ................................... 73
7.4.3 Electrical connections .................................................................. 78
CONTENTS
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7.5 Zero adjust ....................................................................................................79
7.5.1 Preparing the system for zero adjust ...........................................79
7.5.2 Fine adjustment on the optical axis on the SR-unit ....................79
7.5.3 Performing zero adjust .................................................................80
7.6 Starting measuring operation.......................................................................81
7.6.1 Installing the purge air fixtures ....................................................81
7.6.2 Purge air units start-up.................................................................81
7.6.3 Sender/receiver unit and reflector start-up ................................82
7.6.4 Installing the weatherproof cover for the SR-unit .......................84
7.6.5 Installing the weatherproof cover for the purge air units ...........84
7.6.6 Evaluation unit start-up ................................................................85
7.6.7 Setting up the SCU System Control Unit .....................................86
8 Maintenance.............................................................................................88
8.1 Safety.............................................................................................................88
8.2 Preparation and general preparatory work ..................................................89
8.3 Maintenance work on SR-unit and reflector ................................................89
8.3.1 Visual inspection and enclosure cleaning ...................................89
8.3.2 Cleaning the optical interface (window) on the SR-unit..............90
8.3.3 Cleaning the optical interface (window) on the reflector ............91
8.3.4 Checking the zero point................................................................91
8.3.5 Checking optical alignment ..........................................................92
8.3.6 Checking the IR source.................................................................93
8.4 Maintenance work on the purge air supply .................................................94
8.4.1 Preparation and general inspection ............................................94
8.4.2 Checking and replacing the purge air filter .................................95
8.4.3 Restarting and checking the purge air unit .................................96
8.5 Evaluation unit (EvU).....................................................................................97
8.6 Box Measuring...............................................................................................98
8.6.1 Determining the necessary test gas concentration ....................98
8.6.2 Carrying out measurement...........................................................98
8.6.3 Restart Measuring mode........................................................... 100
8.7 Filter box measurement for checking the measuring ducts of H
2
O and
CO
2
.............................................................................................................. 101
8.7.1 Setpoint values .......................................................................... 101
8.7.2 Carrying out measurement........................................................ 102
8.7.3 Restart Measuring mode........................................................... 103
9 Troubleshooting and Clearing Malfunctions..................................... 104
9.1 Malfunction categories/possible effects .................................................. 104
9.2 Purge air failure.......................................................................................... 105
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9.3 Integrated monitoring and diagnosis system ............................................106
9.3.1 Troubleshooting and clearing malfunctions, evaluation unit ...107
9.3.2 Error messages ..........................................................................108
9.3.3 Warning messages for the GM35 SR-unit.................................110
9.3.4 Further tips on troubleshooting .................................................112
10 Technical Data, Consumables and Spare Parts...............................113
10.1 Measuring components and accuracy.......................................................113
10.1.1 GM35 system component..........................................................114
10.2 Dimension drawings ...................................................................................116
10.2.1 GM35 SR-unit dimensions .........................................................116
10.2.2 Purge air fixtures dimensions ....................................................117
10.2.3 GM35 reflector dimensions .......................................................117
10.2.4 Flange with tube dimensions .....................................................118
10.2.5 Dimension drawing of GM35 evaluation unit, sheet metal
enclosure ....................................................................................118
10.2.6 Dimension drawing for GM35 evaluation unit, cast metal
enclosure ....................................................................................119
10.2.7 Purge air unit dimensions ..........................................................119
10.2.8 Weatherproof cover for purge air unit(s) dimensions...............120
10.2.9 Weatherproof cover for SR-unit dimensions .............................120
10.2.10 Terminal box for CAN bus connection dimensions ..................121
10.3 Accessories, expendable and spare parts.................................................121
10.3.1 Consumable parts for 2-years operation...................................121
10.3.2 Spare parts for the sender/receiver unit ..................................122
10.3.3 Spare parts for the reflector unit ...............................................123
10.3.4 Spare parts for purge air fixture – SR side ...............................123
10.3.5 Spare parts for purge air fixture - reflector side .......................124
10.3.6 Spare parts for the evaluation unit ...........................................124
10.3.7 Spare parts for purge air unit ....................................................125
10.3.8 Fixing accessories ......................................................................125
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SAFETY INFORMATION
1 Safety Information
The following information and guidelines apply to the Gas Analyzer GM35 described in this
“Operating Instructions” document, and are valid for all user groups performing any work
on or using the analyzer.
1.1 Permissible users
All planning, assembly, installation, start-up, maintenance and repair work must be carried
out by adequately instructed personnel only and checked by skilled persons.
Persons responsible for safety must ensure the following:
• All safety-relevant work is carried out by qualified personnel only.
• Qualified persons are those who, based on their training, experience or instruction as
well as their knowledge of relevant standards, regulations, accident prevention rules and
plant conditions, are authorized by those responsible for safety for personnel and the
plant to carry out such work. It is decisive that these persons can recognize and avoid
possible hazards in a timely manner. Skilled persons are persons according to
DIN VDE 0105 or IEC 364 or directly comparable standards such as DIN 0832.
• These persons have access to the documentation supplied with the system as well as the
relevant technical documentation for all work carried out, and these persons adhere to
the information in this documentation in order to prevent danger or damage.
1.2 Correct handling
To ensure safety precautions are observed and the device is used for its intended purpose,
it is important that:
• The system be used in accordance with the technical data and specifications regarding
permissible usage, assembly, connection, ambient, and operating conditions. These
conditions are governed by the order documents, user device information (type plates
etc.), as well as the documentation supplied with the system, which includes the
Operating Instructions.
• Users act in accordance with local, system-specific conditions and with due
consideration paid to operational hazards and specifications.
• All measures necessary for conservation of value are observed, e.g. during transport and
storage and/or maintenance and inspection.
1.3 Safety
Basic measures to prevent property damage and injury to persons
Improper usage or improper handling of the Gas Analyzer GM35 can damage health or
material.
WARNING: Risk through incorrect use
Equipment-internal protection devices can be impaired when the device is not
used as defined.
▸ Read the Manual before installation, start-up, operation and
maintenance and observe all information on using the equipment.
NOTICE: Responsibility for the safety of a system
The safety of the system in which the equipment is integrated is the
responsibility of the person setting up the system.
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SAFETY INFORMATION
▸ Therefore, in order to prevent damage, the relevant safety information and valid safety
regulations must be observed.
If the GM35 is used as a sensor in combination with a control system, the operator must
ensure that a failure or malfunction on the GM35 cannot lead to unallowed hazardous
operating states or damage.
Protection against hazards through electrical equipment
GM35 system components include electrical equipment designed for use in industrial high-
voltage plants where the relevant standards and regulations must be observed.
▸ Disconnect mains lines before working on mains connections or live parts.
Protection against hazards through gases
▸ Wear suitable protective clothing and mask when using hot and/or aggressive sample
gases resp. with high dust loads.
▸ Never open the enclosure or switch off the purge air feed without taking appropriate
protective measures when the duct is pressurized.
Troubleshooting precautions
The operator must ensure that:
• Maintenance personnel can be alerted immediately and at any time.
• Maintenance personnel are trained to be able to respond to malfunctions on the GM35
and correctly clear the operational malfunction involved.
• Suitable protective equipment, tools and auxiliary means are available at all times.
• Malfunctions are analyzed by qualified personnel, faults corrected, and operation
optimized to prevent similar malfunctions in the future.
1.4 Behavior during purge air failure
GM35 measuring system configurations demand immediate measures to protect the
measuring system should the purge air supply fail.
▸ Measures for purge air supply failure, see “Purge air failure”, page 105.
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PRODUCT OVERVIEW
2Product Overview
2.1 Use and proper application
The GM35 in-situ gas analyzer continuously measures the concentration of CO
2,
H
2
O and
CO or N
2
O, and in gas ducts – as single or simultaneous measurement depending on the
device variant. As in-situ measuring system, the GM35 determines the measured values
directly in the duct carrying gas without extracting any samples.
• Emission monitoring
The GM35 determines and quantifies pollutants and reference values in gases reliably,
quickly and precisely.
• Process analysis and control
The reliability, precision, and short response time of the GM35 are decisive advantages in
the efficiency of control circuits in all processes creating CO,N
2
O, and CO
2
. Incinerating
and drying plants are reliably monitored and efficiently controlled.
2.1.1 Conformities and certifications
Many areas of application require conformity with certain specifications. The Gas Analyzer
GM35 complies with the following requirements:
• Guidelines regarding qualification tests for measuring equipment intended for
continuous emission measurements
• Conformity in accordance with EN 14181 and suitability for emission measurement in
plants pursuant to the 17th BImSchV and the TI AIR for components CO, CO
2
and H
2
O
(Cross-Duct and GMP-measuring probe versions)
• Conformity with the GOST regulation, Certificate No. DE.C.31.001.A No. 11933
• Conformity with the U.S. EPA regulation CFR 40, Parts 60, 75 and 29 CFR 1310
• EMC conformity in accordance with EN 50081-1/EN 50082-2
CE certification in accordance with EC Directive EMC 89/336/EEC
• The manufacturer SICK AG is certified according to ISO 9001
• EC Directive LVD 2006/95/EC
• EU Directive EMC 2004/108/EC
• Applied EN standards:
• EN 61010-1, Safety requirements for electrical equipment for measurement, control and
laboratory use
• EN 61326, Electrical equipment for measurement, control and laboratory use - EMC
requirements
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2.1.2 Overview of standard components
Fig. 1: GM35 system overview
• Sender/receiver unit (SR-unit)
Contains the main optical and electronic subassemblies of the measuring system. The
gas concentration is recorded here and the measured value determined. Components
CO or N
2
O, CO
2
and H
2
O are measured, both singly and simultaneously in combinations.
• Measurement reflector
Version with a gold-plated hollow triple for the following distances (flange on SR side to
flange on reflector side):
0.5 to 1 m, 1 to 2.3 m, 2.3 to 4 m, 4 to 6 m, > 10 m
• 2 purge air units
Provide purge air for the SR-unit and the reflector and therefore protect against
contamination and high gas temperatures. The blower types for the SR-unit resp.
reflector are designed differently depending on the application.
• Purge air fixtures for the SR-unit and reflector
To fit the SR-unit and reflector on the mounting flanges. These include the purge air
connections to connect the purge air hoses from the purge air unit and sockets for the
connection cable as well as to connect external sensors (purge air unit filter monitor,
temperature sensor PT1000, on the SR side)
• Evaluation unit
The evaluation unit in the GM35 measuring system serves as user interface and
prepares and outputs the measured values and performs control and monitoring
functions. The EvU can be installed near the SR-unit; if necessary, however, it can also
be installed up to 1000 m from the measuring point, e.g. in a central control/monitoring
room in an industrial plant.
The evaluation unit carries out the following tasks, for example:
Sender/receiver unit
(SR-unit)
Reflector
Purge air fixture
SR-unit
Purge air fixture
for reflector
Purge air unit SLV4 SR-unit
Purge air unit SLV4
Reflector
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– Output of measured values, computed data and operating states
– Communication with the peripheral equipment
– Output of error messages and other status signals
– Control of automatic test functions and access during service (diagnosis)
• Connection cables
• Flanges with tube
To install the SR-unit and reflector on the gas duct. The purge
air fixtures onto which the SR-unit and reflector are later
mounted are secured to the flanges. Dimension drawing and
order data, see page 118. ANSI or DIN flanges provided by the
customer can be used alternatively to the flanges supplied.
Cable type Part No.
Cable
*)
(CAN bus), SR-unit – purge air fixture, length 0.8 m
Connection cable
[1]
, 5, 10, 12, 15 or 24 m available as accessory.
2023704
Cable
[2]
(CAN bus), SR-unit – evaluation unit, length 4 m
Scope of
delivery
Cable
*)
, purge air fixture SR-unit – filter monitor for purge air unit, length
5 m;
2032143
2 cables
*)
, purge air fixture SR-unit – filter monitor for purge air unit,
length 2 m as extension;
6025923
Cable, purge air fixture SR-unit – filter monitor for purge air unit, length
3 m as extension
6028663
[1] One length included in scope of delivery
[2] Included in scope of delivery
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PRODUCT OVERVIEW
2.2 Device components
Fig. 2: Standard GM35 components
Sender/receiver unit
Evaluation unit
Purge air fixture for sender/
receiver unit
Reflector
Purge air fixture for reflector
SLV4 purge air unit for
sender/receiver unit
SLV4 purge air unit for
reflector
Version
Cast metal enclosure (IP 67)
Version
Sheet metal enclosure (IP 65)
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PRODUCT OVERVIEW
2.2.1 GM35 options and accessories
• Cover plate for purge air fixture of the sender/receiver unit
to maintain purge air supply in cases where this must remain in operation at the
measuring location when the SR-unit is dismounted.
• Weatherproof covers for SR-unit and purge air unit
required for outdoor installation – dimension drawings, see “Dimension drawings”,
page 116.
• Chart recorder, single or multi-channel
for measured value recording. Protocol(s) can of course be produced using customer sys-
tems.
• Air heater for purge air supply
for special application conditions to prevent condensate. An air heater is required when
the difference between gas temperature and dew point temperature is too low. The
following practical rule of thumb serves as guideline:
An air heater is required when
gas temperature [°C] – dew point temperature[°C] < abs. humidity [%].
Values are compared without considering the units of measure.
A Data Sheet for the fan heater is also available under Part No. 8 008 330.
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PRODUCT OVERVIEW
2.3 Functional principle
2.3.1 Opto-electronic in-situ measuring principle
The Gas Analyzer GM35 is based on the in-situ technique using opto-electronic direct
measurement. Measured values are recorded through no-contact measurement directly in
the gas flow across the entire duct cross-section (cross-duct). The GM35 SR-unit
determines the concentration of the respective gas component based on wavelength-
specific light absorption by the gas mixture in the active measuring path.
Fig. 3: Optics layout for the GM35
The beam from the sender/receiver unit (SR-unit) passes lengthwise through the active
measuring path (see see “Fitting recommendation for the mounting flange (duct diameter
not representative)”, page 20) and is reflected by the reflector at the other end. The
reflected light from the beam splitter then passes through a filter or cell wheel to detectors
configured optionally to measure CO, N
2
O as well as CO
2
and H
2
O. By filtering the light
received into its spectral components, the receiver elements record the absorption of the
gas molecules at characteristic points of the spectrum in the IR range of 1.6 to 4.9 μm.
Cross-sensitivities with gases other than those to be measured are avoided by selecting
these evaluation ranges within the IR spectrum in conjunction with the evaluation algo-
rithms used (see “Signal evaluation”, page 15).
CO or
N
2
O detector
Measuring path in gas duct
Cell wheel and detector
for CO- or N
2
O measurement
IR transmitter
lamp
Zero point reflector
and blanking diaphragm
Filter Fwheel and detector
for CO
2
and H
2
O
Reflector
Reference filter for pivoted
segment
Visor with opto-electronic adjustment tool
Filter wheel and detector
or CO
2
and H
2
O
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PRODUCT OVERVIEW
2.3.2 Signal evaluation
The optimized algorithms of the GM35 evaluation electronics process the measurement
signals of the receiver elements together with the associated parameters in accordance
with the correlation procedure with optical filters for CO
2
and H
2
O and with cells filled with
CO or N
2
O.
Fig. 4: Evaluation of absorption spectrums for sample gases with the GM35
2.3.3 Automatic check cycles
To ensure a consistently high level of measuring precision, the GM35 SR-unit performs a
regular automatic check cycle in an adjustable interval (standard: Every 2 hours). In this
check cycle, the zero point is first determined by swiveling a zero point reflector into the
CO
CO
2
H
2
O
2000 2500 3000 3500 4000
λ
[nm]
4500 50001500
18001600 2000 2200
Ref. 2 H
2
OCO
2
Ref. 1
Absorption
H
2
OCO
2
46004400 4800 5000
CO
N
2
CO
4600 4800 4600 4800
CO
2
and H
2
O measurement in
the range of 1600–2200 nm
CO measurement in the range
of approx. 4500–4900 nm
Cell wheel
N
2
/CO
Absorption CO
≈ measured value
Absorption CO
= 100%
Filter wheel for
CO
2
and H
2
O
Reference filter for determining the
background absorption, free of cross-
sensitivities with other gas components
The CO or N
2
O measured values are
determined from the signals at the
detector with absorption by the sample gas
and with a cell filled with the component to
be measured. Interference is eliminated.
Transmission
characteristic line
of the CO
measurement filter
Absorption
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PRODUCT OVERVIEW
beam path. Reference filters are then moved into position to control the check point. The
spectral properties of the device are checked using a test gas cell. If a check cycle reveals
that the system is not functioning in accordance with the operation specifications, the
GM35 measuring system outputs appropriate error or warning messages.
Triggering options
1 Di 1 (falling edge): The check cycle can also be suppressed with this function.
2 Time interval, adjustable via the menu of the EvU.
Sequence
1 Check cycle is started.
2 Internal reference measurement is executed. Signal: Relay 3 (function check)
3 The zero point and check point are output on the EvU display and the assigned analog
outputs for 90 seconds each.Relay 3 remains active.
Fig. 5: Determining the check point
Observe the following for connecting to an emission computer: Measure the
time from the start to the output to compensate differences in the device
settings.
Measuring
Zero point
Check
Zero point
Check point
(70% fsc)
Zero point reflector
Swivel element
Data recorder
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PROJECT PLANNING INFORMATION
3 Project Planning Information
3.1 Work steps from system selection to start-up
Application changes
If the information regarding your application submitted with your purchase order has
changed, or if a device is to be used for an application other than the one that was
originally
intended, please contact your local sales representative or our project planning
department to determine whether the device(s) can be used under the new conditions, and
whether readjustment or reparametrization is necessary.
The following steps are generally carried out before the measuring system is started up:
• Project planning
See planning checklist below
• Initial onsite installation
The following preparations, usually carried out by the customer, are described in “Initial
onsite installation”, page 20.
• Flange assembly, see “Installing the flanges with tube”, page 21.
– Preparations for installing the purge air unit, see “Installation preparation for the purge
air unit”, page 24.
– Laying the signal and power supply cables to the measuring point, see “Duct insulation”,
page 24.
– Preparations for installing the EvU, see “Installation preparation for the evaluation
unit”, page 25.
– If necessary, preparing the signal cables for the interfaces to the peripheral equipment,
see “Preparations for electrical installation”, page 25.
• Device installation
To allow speedy start-up, the following components are normally installed ready for
operation before the start-up date; see also “Installation”, page 30.
– Purge air unit
– Evaluation unit
• Start-up
The actual start-up procedure is carried out by trained personnel or SICK Customer Ser-
vice. This work is described on page 69. The main activities are adjustment tasks on the
GM35 system related to the application.
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PROJECT PLANNING INFORMATION
3.2 Project Planning Checklist
Project planning, step by step
Technical data and dimensional drawings of system components, see “Technical Data,
Consumables and Spare Parts”, page 113 and following.
Topic Task Measure/determination
Determining the
measuring point
Observe national
regulations such as
VDI 3950.
Provide for unhindered inlet and outlet paths:
▸ For round duct cross-sections: 3 times the duct diameter
▸ For rectangular cross-sections: Hydraulic diameter
▸ If these specifications cannot be met: Inlet path > outlet path,
e.g.
2
/
3
:
1
/
3
; uniform concentration spread whenever possible
Emission measuring
point
▸ Obtain official approval for emission measuring point.
▸ Provide for calibration openings at easily accessible places.
▸ Ensure the GM35 and calibration probe do not influence
each other; the calibration gland should be located at a
minimum distance of 0.5 m upstream of the measuring
device.
Application conditions
▸ Observe Technical Data for duct/ambient conditions!
▸ Gas temperature above/below dew point (dry/wet)
Pressure conditions at
the measuring point
▸ A fitting location with partial vacuum in the duct is ideal.
▸ For duct pressures > 10 hPa/mbar, please contact SICK to
select the correct purge air blower type.
SR-unit, reflector
see “Assembly prepara-
tion at the measuring
point”, page 20.
Select suitable flange
with tube
● The flange is designed to be installed in steel ducts; suitable
flanges with tube are usually supplied with the GM35.
● Stone stacks or ducts with thick walls demand an onsite
retaining plate and, possibly, a longer version of the flange
with tube; see “Installing the flanges with tube”, page 21.
● If some of the components have not yet been delivered, you
may need to arrange an advance delivery of the flanges with
tube so that you can mount these as part of the
preparations for installation onsite.Alternatively, you can use
a suitable flange prepared onsite (or ANSI flange, check the
Technical Data, see see “Technical Data, Consumables and
Spare Parts”, page 113).
Select stack opening
▸ Provide an opening of suitable size for the flange tube.
▸ Provide for adequate clearance for installation and
maintenance activities for the duct insulation cutout.
▸ Plan clearances for handling the SR-unit, reflector.
▸ Ensure the ambient temperature for the SR-unit and
reflector is between –20 and +55 °C (–40 °C during
continuous operation).
▸ For installation outdoors, plan a weatherproof cover
Tools for start-up and
maintenance
● When working on the zero path; prerequisites: Clean
ambient atmosphere free from sample gas; weatherproof:
Plan the zero path or order from SICK.
Table 1: Project planning checklist
D
4F (Cross-sectional area)
U (Circumference)
-------------------------------------------------------------------------------------=
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PROJECT PLANNING INFORMATION
Purge air unit
see “Installation prepara-
tion for the purge air unit”,
page 24
Fitting location
selection
▸ Plan installation location on the duct in immediate vicinity
(5 m) of the GM35 SR-unit.
▸ Keep purge air hoses to the respective purge air fixture
(SR-unit, reflector) as short as possible (pressure drop per
meter, approx. 1.2 hPa/1.2 mbar).
▸ Ensure secure cable laying.
▸ Ensure dry and, whenever possible, dust-free intake air on
the purge air unit, use a preliminary filter when necessary.
▸ The intake air temperature should be between 0 and
55 °C. Heat the purge air when T < 0 °C; see air heater
option.
▸ For installation outdoors, plan a weatherproof cover.
Evaluation unit
see “Installation prepara-
tion for the evaluation
unit”, page 25
Determine the fitting
location
▸ Install the evaluation unit at an easily accessible location,
preferably at the measuring point. If necessary, install it at
a distance from the measuring point, whereby the total
length of all the CAN bus connections in the GM35
measuring system must not exceed 1000 m.
● Ambient temperature between –20 °C and +55 °C.
● During continuous operation –40 °C.
Options for CAN bus
wiring
▸ Is the 4 m CAN bus cable sufficient for the connection
between EvU and SR-unit at the selected installation
location?
If not, select a suitable cable (see see page 11):
▸ If the distance is less than 19 m: Plan a 15 m prefabricated
CAN bus cable with plug-in connectors.
▸ For larger distances: Use CAN bus terminal boxes and a
cable provided by the customer.
Assembly platform Specify the assembly
platform
▸ Provide a suitable working platform for installation on the
outside of a duct/stack.
▸ The fitting location of the GM35 SR-unit should be about
1.3 to 1.5 m above the platform.
▸ The platform must be large enough, secured and positioned
so that all device parts can be accessed without danger.
This is especially important when inserting and removing
the SR-unit or reflector.
Accident prevention Applicable (national) regulations on accident prevention must be observed.
Always observe and follow the relevant safety information provided for the
corresponding texts in these Instructions.
Topic Task Measure/determination
Table 1: Project planning checklist
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PROJECT PLANNING INFORMATION
3.3 Initial onsite installation
The following work can be carried out by the customer's technicians. Requirement: The
project planning checklist has been processed beforehand.
3.3.1 Assembly preparation at the measuring point
This Section describes the welding work on the duct including making fixing elements
onsite.
Fig. 6: Fitting recommendation for the mounting flange (duct diameter not representative)
3.3.2 Uncovering the duct
▸ If necessary, remove approx. 800 x 1500 mm (W x H) of the duct insulation to be able to
access the duct during subsequent work.
▸ Keep the insulation material removed for later refitting resp. provide new suitable
insulation material.

Duct wall (steel)
Duct insulation
Flange with tube,
standard: L = 240 mm
Working platform
1.3 – 1.5 m
Distance to SLV4
min. 700 mm
Markings for fitting position, pointing
in flow direction
Active measuring path
Flange – flange distance:
CAUTION: Protective measures at the measuring point
▸ Always shut down the installation before any work on the duct!
▸ Secure parts to be separated with, for example, wire binding, to prevent
damage by falling objects.
▸ Take appropriate protective measures against hot, explosive gases or toxic
gases that could possibly escape from the duct.
▸ If necessary, seal off the mounting flange with a cover securely until device
assembly (e.g. for overpressure in duct).
/